EP0560873A1

EP0560873A1 - Method and device for producing and conditioning a sterile expandded food preparation, and sterile expanded food preparation obtained with such method.

Info

Publication number: EP0560873A1
Application number: EP92901136A
Authority: EP
Inventors: Jean-Marie Bossu; Annie Bossu
Original assignee: AJMB
Current assignee: AJMB
Priority date: 1990-12-03
Filing date: 1991-11-29
Publication date: 1993-09-22
Anticipated expiration: 2011-11-29
Also published as: FR2669811B1; ATE119354T1; EP0560873B1; WO1992009213A1; DE69108051T2; FR2669811A1; DE69108051D1

Abstract

The invention relates to an expanded food preparation based on meat, fish, milk product, fruit, vegetable, chocolate or a mixture of such products, charaterized in that it is sterile and that it contains an expanding base including: a) one or a plurality of foaming surfactants, resisting to a temperature higher than 100 C, preferably about 120 C selected particularly amongst proteins, b) one or a plurality of texture stabilizers selected particularly amongst gums, the agents a) and b) being included in proportions such that the food preparation obtained has a density lower than 1, preferably between 0.9 and 0.3 and preferably on the 0.7. The invention also relates to a method and device for the production of said food preparation.

Description

Method and device for manufacturing and packaging a sterile expanded food preparation, and sterile expanded food preparation obtained with such a method

The present invention relates to a process and a device for manufacturing and packaging a sterile expanded preparation based on at least one food product, and a food preparation obtained by the implementation of such a process.

The sterile expanded food preparation can be, for example, based on meat, fish, dairy products, fruit, chocolate, vegetables or a mixture of these products.

By sterile food preparation is meant in the context of the invention, a preparation meeting the standards in force in the field of sterile food products. In this regard, we can refer to the definitions given in works such as LE NOUVEAU DEHOVE - Commerce Edition Paris by Raymond A. DEHOVE (1984). These are, in particular, products which have been "sterilized" by bringing them to a temperature above 100 ° C. By expanded food preparation is meant a food preparation of heterogeneous structure containing a food product of more or less pasty texture, ranging from liquid to solid, constituting the continuous phase, and a gas or air forming the dispersed phase.

Reference will also be made to the definitions in the literature on abundant food preparations, also identified as colloidal food "foams". The invention finds a particularly important although not exclusive application, in the field of food preparations based on meat products, in the form of expanded foams, and for example intended for the use of people with masticatory problems such as babies or the elderly.

Processes and devices are already known for the continuous production of a non-sterile expanded food preparation. For example, a process is known of the type in which a dough is formed by mixing the food product, previously chopped if necessary, with an abundant base comprising at least one foaming surfactant and at least one stabilizing agent. texture. A first heat exchanger, said scraped surface heat exchanger, is then continuously fed with the dough, where the dough is stirred at a first temperature, for a first determined time.

A scraped surface exchanger is an exchanger known from the prior art, consisting of two horizontal or vertical coaxial tubes. The inner tube through which the product to be treated flows, is scraped by blades or knives attached to a central rotor. The thermal fluid (steam, cold water, hot water, etc.) circulates against the current or co-current in the annular space between the two tubes.

In this known type process, a second scraped surface heat exchanger is then fed continuously from the first scraped surface heat exchanger, where said paste is again stirred or scraped for a second time determined by the heating to a second temperature.

Simultaneously, when the dough passes through these exchangers, an inert gas is continuously injected into the dough with a determined flow rate, depending on the flow rate. feeding the dough; finally fed continuously with the paste, a third heat exchanger with a scraped surface, where the said paste is stirred for a third determined time by cooling it to a third temperature.

This type of process is currently known for pasteurized preparations.

There are also other methods and devices applied to the manufacture of sterile preparations which are not expanded.

All of these known methods currently have drawbacks. Indeed, they do not make it possible to obtain food products which are both abundant and sterile.

In particular, a process such as that of the type described above is not known for the manufacture of sterile preparations. Its use could not, in fact, come to the idea of a person skilled in the art taking into account, in particular, the results of various studies, which showed that heating an expanded dough at a temperature above about 80 ° C., seemed to prevent the obtaining of an abundant food preparation of satisfactory quality. In fact, it has for example been observed that, when a swelling foam, of density less than 1, and in particular less than 0.7 relative to water, is brought to a temperature above 100 ^β C, the preparation tends on the one hand to lose its consistency of foam to take that of a classic pâté, and on the other hand to present poorer organoleptic qualities.

Furthermore, the packaging of a sterile expanded food preparation having always seemed to pose implementation problems to those skilled in the art, the manufacture of such a preparation did not seem to can be exploited industrially and was therefore not envisaged because of this.

The present invention aims to provide a method,. . . . . . a device and a food preparation which respond better than those previously known to the requirements of practice, in particular in that they allow the manufacture and packaging of a food preparation which is both expanded and sterile, in a reliable manner, while meeting the health standards in force and allowing industrial production of food preparations in large quantities.

It is recalled that the expansion is the given volume / weight ratio and is equivalent to the density.

To this end, the invention provides in particular a method of manufacturing and packaging a sterile expanded preparation based on at least one basic food product in particular included in the products envisaged, characterized in that from a paste prepared by mixing the food product, previously chopped if necessary, with an abundant base comprising at least one foaming surfactant and at least one texture stabilizing agent, a thermal treatment of bacterial destruction and cooking of the dough comprising a step of brewing in a heat exchanger with a scraped surface of said dough by heating it to a temperature between about 100 ° C and about 130 ° C for a determined time, by injecting a gas in said paste during said heat treatment, to obtain a sterile expanded preparation, then the preparation is cooled to a temperature below about 40 ° C. , the agents being in proportions such that, taking into account the quantities of gas injected and of paste used, the expanded preparation formed after cooling has a density relative to water of less than 1, preferably less than 0.9 and particularly advantageously less than 0.7, and in that said expanded preparation after cooling in previously sterilized containers, which is then sealed in a hermetic and sterile manner, so that portions of preparation are thus obtained packed sterile, long shelf life at room temperature.

Indeed, surprisingly, the inventors were first able to show that by increasing the temperature of the heat treatment of the dough beyond 100 ° C., in a heat exchanger with a scraped surface and under the conditions indicated below. above, the shape and consistency of foam of the expanded preparation obtained remained satisfactory, contrary to popular belief.

Then, the inventors succeeded in carrying out a conditioning of the preparation obtained with equipment allowing high processing rates, thus demonstrating the feasibility of packaging in large quantities of a sterile expanded preparation. In doing so, they have therefore resulted in the present invention residing in particular in the combination of the manufacture of a sterile expanded food preparation with a packaging of said preparation, that is to say a placing in closed containers allowing a long conservation preparation time, for example up to 6 months or 1 year, and this again, contrary to popular belief in this area.

In an advantageous embodiment, the heat treatment for bacterial destruction and cooking comprises a first step in which the dough fed continuously is stirred in a first exchanger with a scraped surface, by heating said dough to a temperature of between approximately of 50 ° C and of the order of 80 ° C, for a first determined time, and a second step in which said dough is continuously fed from the first exchanger, in a second exchanger with a scraped surface, by heating the dough at said temperature between around 100 ° C and around 130 ° C, for a second determined time, the cooling being carried out in a third exchanger with a scraped surface, supplied continuously from the second exchanger , where the dough is stirred for a specific third time.

The implementation of these three stages, where are observed _. the above-mentioned temperature conditions make it possible to obtain an abundant sterile food preparation with a very good texture which is particularly well maintained over time.

Advantageously, the times determined are between about 1 minute and about 5 minutes.

The times determined are average residence times (t). They are calculated from the mass flow rate M of the preparation, the average p of the densities of the preparation at the inlet and at the outlet of the exchanger, and from the internal volume V of the exchanger. t stay = px VM The determined times are for example expressed with the following units:

[m3] [kg / m3] [mn] =

[kg / min] The invention also provides a process for the continuous manufacture and packaging of an expanded preparation based on at least one food product, of the type defined above, that is to say in which : a dough is formed by mixing the food product, previously chopped if necessary, with an abundant base comprising at least one foaming surfactant and at least one texture stabilizing agent chosen in particular from the gums, continuous with said paste a first scraped surface heat exchanger, where said paste is stirred for a first determined time by heating the paste to a first temperature, then continuously fed with the paste thus obtained a second scraped surface heat exchanger , where said dough thus obtained is brewed for a second determined time by heating the dough to a second temperature, an inert gas is continuously injected into the dough simultaneously t at its supply, upstream and / or downstream of the first and / or the second exchanger, with a flow rate determined as a function of the feed flow rate of said paste, then a third surface heat exchanger is continuously fed with the paste scraping, in which said dough is stirred for a third determined time by cooling the dough to a third temperature, said process being characterized in that the agents are in proportions such that, taking into account the quantities of gas injected and of paste used, the expanded preparation formed has a density relative to water of less than 1, preferably between 0.9 and 0.3 and particularly advantageously less than 0.7, in that the first temperature is between about 50 ° C and about 80 "C, the second temperature is between about 100 ° C and about 130 ° C, and the third temperature is between about 10 ° C and about 40 "C, said determined times, duration mean brewing, being between about lmn and about

5 min, so that a sterile expanded preparation is obtained from said paste, and in that anseptic medium is supplied with said sterile expanded preparation, immediately after cooling, to a packaging unit located near said third exchanger, conditions the preparation, by automatically feeding aseptic medium with said preparation, previously sterilized containers, then hermetically sealed and sterile, so that one obtains portions of sterile expanded preparation packaged, long storage at room temperature.

In advantageous embodiments, one or both of the following provisions are used: -

- the food product is meaty; - The second temperature is greater than 120 ° C and advantageously equal to around 125 ° C; the abundant base includes several agents

5 foaming surfactants chosen among. sodium casemate, egg white, whey isolate, soy isolate, pea isolate, skimmed milk powder, pork blood plasma powder, preferably so that that the amount of proteins in pure ^u provided soi.t i.nféri.eure to 10%, and advantageously equal to 1'ordre 6% by total weight of the preparation; the abundant base comprises several stabilizing agents of texture chosen from gums such

¹⁵ as xanthan, guar, carrageenans, these stabilizing agents being in a proportion of about 0.1% to

1%, and advantageously 0.5% by total weight of the preparation.

- the abundant base includes:

20. between 0.5 and 2% by weight, preferably between 1 and

1.5% sodium caseinate,

. between 0.5 and 2% by weight, preferably between 1 and 1.5% of powdered egg white,

. between 2 and 6% by weight, preferably between 4 and 5% 5 of whey isolate,

. between 1 and 3% by weight, preferably 2% to 3% of altodextrins, and

. between 0.2 and 1% by weight, preferably 0.5% of carrageenans. 0 Whole pieces of said product are incorporated into the dough comprising the product, previously chopped if necessary, before the heat treatment. These pieces can for example be cubes of 2cm x 2cm. 5 The invention also provides a device for the continuous production of a food preparation which is expanded with a dough prepared by mixing at least one food product, previously chopped if necessary, with an abundant base comprising at least one agent. foaming surfactant and at least one texture stabilizing agent, the device comprising:

means for supplying pressure and continuously at a determined flow rate, with said paste, to a first scraped surface heat exchanger,

two exchangers with a scraped surface for heat treatment and cooking of the dough, namely said first exchanger, and a second exchanger, a third exchanger for cooling the dough, and

means for injecting a gas into the dough with a flow rate determined as a function of the feed flow rate of said dough, characterized in that the device comprises:

- means for heating the dough in the first exchanger, at a temperature between around 40 ° C and around 80 ° C, and in the second exchanger at a temperature between around 100 ° C and around 130 ° C,

means for cooling the dough in the third exchanger, to a temperature below about 40 ° C., so that a sterile expanded preparation is obtained from said dough, suitable for being packaged, and in what it entails

means of conveying said sterile expanded preparation in an aseptic medium immediately after cooling, to a packaging unit located near said third exchanger, - and said packaging unit comprising means for automatically supplying aseptic medium with said preparation, previously sterilized containers and means for sealing in an automatic, hermetic and sterile of said containers, so that portions of sterile expanded preparation are thus packaged in said sealed containers, long storage at room temperature.

Advantageously, the device is applied to the production of a sterile expanded preparation based on meat products such as, for example, ham.

In another advantageous embodiment, the device further comprises a fourth heat exchanger with a scraped surface, for progressive heating and for baking the dough. Advantageously, the heat exchange surfaces of the scraped surface exchangers of the device according to the invention are in the following proportions: 1st exchanger: ax m2 2nd exchanger: ax m2 third exchanger: ax 1.5 x m2 a indicating a surface variable, for example between 0.12 m2 and 1.7 m2.

The invention also relates to a food preparation as obtained by implementing the manufacturing process described above.

This food preparation can also be defined as being an abundant food preparation based on meat, fish, dairy product, fruit, vegetable, chocolate or a mixture of several of these products, characterized in that it is sterile and that it contains an abundant base comprising: a) one or more foaming surfactants, resistant to a temperature above 100 ° C., preferably to a temperature in the region of 120 ° C. chosen in particular from proteins, b) one or more texture stabilizing agents chosen in particular from gums, agents a) and b) being in proportions such that the food preparation formed at a density less than 1, preferably between 0.9 and 0.3 and particularly advantageously, less than 0.7. Advantageously, this invention is as obtained by mixing one or more of these products with an abundant base comprising: a) one or more foaming surfactants, resistant to a temperature above 100 ° C., preferably around 120 ° C chosen in particular from proteins, b) one or more texture stabilizing agents chosen in particular from gums, agents a) and b) being in proportions such that the food preparation formed at a density less than

1, preferably between 0.9 and 0.3 and particularly advantageously, less than 0.7.

- Sterilization by heating at a temperature between around 100 ° C and around 130 ° C for a time greater than around 1 min. The food preparations according to the invention are in the form of a foam and can be used in completely different circumstances, in particular for feeding in hospital regi.me. These foams being presented in the form of sterile products, the surface-active agents which can be used for the preparation of this preparation must be capable of withstanding a temperature applied in particular during the sterilization phase of the product.

Possibly some products of the food preparation are present in the form of pieces. In this case, the quantity of pieces is advantageously less than 25% by total weight.

It should be noted that the preparations of the invention have quite interesting organoleptic and nutritional qualities and in particular that the vitamins and mineral salts are preserved.

As indicated above, by sterile product is meant in the context of the invention, a product meeting the standards in force in the field of sterile food products.

To obtain a product whose density is equal to one of the preceding values, account will be taken of the respective quantities of food raw material and of inert gas injected for the production of the expanded preparation. The expansion is also influenced by the temperature of the product at the outlet of the foam preparation device. Effective cooling allows, with the speed and shear stress as well as the viscosity of the product, to improve the degree of expansion.

The respective proportions of foaming surfactants and texture stabilizers are also determined in particular according to the nature of the raw material used for the preparation of the food preparation. One can for example provide that depending on the lipid content of the basic products, a greater or lesser amount of stabilizing and foaming agents should be added. Indeed lipids can under certain conditions harm foaming properties. According to a preferred embodiment of the invention, several surface-active foaming agents will be used as a mixture and several texture stabilizers also as a mixture. Such mixtures of ingredients in the teeming base can improve the stability of some foams, even when prepared from foods that tend to be unstable.

By stable product is meant a product whose sterile character and organoleptic qualities are maintained during storage under conditions given in the preceding pages.

The abundance, determined by the density of the food preparation formed can vary depending on the raw materials used. Thus for the production of a ham mousse comprising few (less than 25%) pieces of meat in the final state, it is advantageously possible to obtain a density of 0.7 or a density which can range up to 0.3.

The various parameters will therefore be adjusted by a person skilled in the art as a function of the basic food product used, and as a function of the desired expansion.

A preferred sterile expanded food preparation according to the invention is such that its lipid content is less than 20%, preferably around 10% by total weight of composition. Depending on their destination, the abundant food preparations can also have a lipid level close to 0. For some of the preparations, for example for hospital use, the lipid content can be between 5 and 6% preferably around 5.5% total weight. The amount of water by weight incorporated into the dough to constitute the product should advantageously be greater than 35% by weight of the dough, and more particularly of the order of 40% to 45%. We can also play on the more or less liquid nature of the dough by adding colloids such as gum arabic in particular with an amount less than about 1% by weight of the dough. In the case where the lipid level is close to 0, the quantity by weight of added water could be of the order of 55%.

The nature of the lipids used in the context of the preparation of the food foams of the invention may also be of some importance. In general, lipids reduce the foaming properties of proteins and it may be advantageous, depending on the nature of the raw materials used, to use lipids of different origin. For example, for the preparation of fish mousse, it is advantageous to use non-polar fats and oils such as vegetable oils.

This particular quality makes it possible to design, in the context of the invention, so-called light food products (as a function of their lipid content) and in particular food products having an energy value of less than 200 kcal / lOOg. The invention therefore allows the production of so-called dietetic food preparations. Optionally, part of the lipids can be replaced by a change agent such as glucose syrup. If necessary, the raw materials such as meat, dairy products, fruits, vegetables or chocolate can undergo a pretreatment before being prepared according to the manufacturing process of the invention to obtain the above food preparations.

In particular for the food preparation of the invention, it is possible to use meat previously cooked according to a chosen process, or it is possible to use the raw materials already mixed with certain agents, for example with flavors, in particular on an alcohol support and / or with various seasonings.

By way of example, foaming surfactants which can be used for implementing the invention are chosen from sodium caseinate, egg white, whey isolate, soy isolate, isolate peas, skimmed milk powder, pork blood plasma, preferably so that the amount of pure protein supplied is less than 10%, particularly advantageously of the order of 6% by weight total.

Mixtures which are particularly advantageous for the development of the preparations according to the invention are characterized in that they contain sodium caseinate, powdered egg white, and a whey isolate. Advantageously, a mixture comprising these constituents will form approximately 10%, preferably 6% of the food preparation, this by total weight.

Particularly preferably, the proportion of ¹ whey isolate is higher, for example 4 times higher than that of caseinate and / or powdered egg white. Egg white and caseinate can be used in relatively identical proportions.

The choice of different foaming surfactants can be made taking into account the properties of the raw materials used. By way of example, it may be mentioned that powdered egg white constitutes an interesting foaming agent for most foods. Powdered pork plasma can be used advantageously for the production of food preparations containing meat, but can also be added to products whose viscosity must remain low and which may require strong emulsification. In this regard, we can cite food preparations based on dairy products.

Sodium caseinate has very interesting properties as a foaming agent and can be recommended for obtaining preparations with a firm structure and for preparations containing a higher proportion of lipids. In particular for products having a lipid content of approximately 20%, this sodium caseinate may prove to be particularly advantageous.

Pea isolate is a lower foaming agent than sodium caseinate, but it provides a more stable foam. The texture stabilizing agents can be chosen from xanthan, guar, carrageenans, these stabilizing agents being present in a proportion of approximately 0.1 to 1% in a particularly advantageous manner approximately 0.5% by total weight. Preferably, a mixture of carrageenans and maltodextrins, for example maltodextrins sold under the brand Passeli SA2. These constituents may for example be present in proportions such that the carrageenans are in a smaller amount compared to the maltodextrins. Particularly advantageously, one part of carrageenans can be used for 4 parts by weight of maltodextrins. Passeli SA2 or any other suitable constituent, in particular from maltodextrins, can be substituted for a certain amount of fat, for example of the order of 50%.

A particularly advantageous preparation is that which is characterized in that it comprises:

- between 0.5 and 2% by weight, preferably between 1 and 1.5% of sodium caseinate, between 0.5 and 2% by weight, preferably between 1 and 1.5% of egg white powder, _ between 2 and 6% by weight, preferably between 4 and 5% of whey isolate,

- between 1 and 4% by weight, preferably 2 to 3% of maltodextrins,

- between 0.2 and 1% by weight, preferably 0.5% of carrageenans.

In the case where water partially replaces lipids, the percentage of carrageenans is advantageously less than 1%, preferably around 0.5%. It is advantageous to add gelling agents chosen in particular from alginates, agar, carob flour, guar flour, gum tragacanth, gum arabic, pectins, karaya, damar, acacia, gelatin . Likewise antioxidants or deaeration of the product can be used to avoid its oxidation when conditioned.

Depending on the nature of the sterile foam produced, it may be advantageous to incorporate food in the form of pieces. It is useful to note that for the stability and the qualities of the foam formed in particular to guarantee the bacteriological qualities, use will be made of pieces of small size and preferably in an amount less than 25% by weight of the overall preparation.

Other components which may enter into the preparation of the food preparation of the invention are for example food additives such as preservatives, colorants, antioxidants, emulsifying, stabilizing, thickening or gelling agents. One can also enter the food preparation of other additives such as natural flavoring substances or not, sweeteners such as intense sweeteners, natural or synthetic ^• eg rare sugars, polydextrose, fructose , glucose syrup, sorbitol, glycerol; anitol, flavor enhancers, binders, ferments, homogenizers, ancillary products in less quantity (alcohol, •••) likely to intervene in the usual manufacture of food. One can also add to the preparation, natural and artificial flavors, for example on an alcoholic support, digestive enzymes, vegetable dietary fibers, pseudo-fats such as calofats, cyclodextrins, acidity correctors. A particularly preferred food preparation according to the invention corresponds to the following definition:

It is important to note that the abundant products according to the invention are sterile products which can be stored at room temperature, in various forms, for example in plastic packaging.

This ham mousse contains about 15.65% protein, 10.20% fat and 4.25% carbohydrates.

The invention is naturally not limited to the production of ham mousse as described above. On the contrary, the means of the invention can be used to manufacture products such as foams of poultry liver, fatty liver, poultry, fish, etc., or any delicatessen product that one would like. example present in spreadable form. One can also use the means of the invention for the preparation of vegetable foams from all kinds of vegetables.

The invention also includes food preparations possibly of the dietary type, which are similar to cooked dishes and comprising mixtures based on meats and vegetables, the mousses being prepared according to the basis of traditional cuisine. Thus, it is possible to prepare blanquette of veal, beef with carrots, pork, turkey, fish or the like, these foams possibly comprising pieces. In the field of dairy products, the food preparations of the invention include cheese-type products which can be spread, foams comprising fruits (pears, strawberries, etc.) and ingredients such as chocolate. All these products are intended for routine food as well as specific food for babies, athletes or the elderly, and the sterile nature of the preparations of the invention allows them to be used in hospitals.

The incorporation of the ingredients in the food preparation of the invention will also be carried out according to the consistency sought for the foam. For example, foams made with high protein concentrations are finer, denser and generally more stable. Likewise, the pH of the composition can influence the behavior of proteins in solution and therefore the stability of the foam. In this regard, it may be interesting to develop food foams whose pH is close to the isolelectric point (pi) of the proteins used. Likewise, the proportion of sugar can influence the degree of profusion; the addition of sugar decreases the profusion but can bring an improvement of the stability. The amount of sugar can therefore be evaluated as a function of the nature of the other constituents, in particular proteins, the sugars being able to have an action on basic and acidic proteins.

The invention will also be better understood on reading the following description of a particular embodiment of the method and the device, given by way of non-limiting example.

The description refers to the accompanying drawings in which: - Figure 1 is a block diagram, in the form of blocks, of the process for manufacturing and packaging a sterile expanded food preparation according to the invention.

- Figure 2 is a block diagram showing more precisely the steps of an advantageous embodiment of the packaging of the sterile expanded food preparation, according to the invention.

- Figure 3 is a block diagram of a device for manufacturing a sterile expanded food preparation, according to the embodiment of the invention more particularly described here.

- Figure 4 is a sectional view, in principle, of a scraped surface heat exchanger, of the type used in the invention. Figure 1 gives the main steps followed in the embodiment of the method according to the invention more particularly described here.

The process comprises two phases, a phase 1 of manufacturing the food preparation, and a phase 2 of conditioning this preparation.

In order to illustrate these different steps, the example of the manufacture and packaging of a particular ham mousse as defined above, serving as a basic product for different ranges of preparations. Phase 1 includes a first step 3 of pretreatment of the raw materials.

In the example chosen, the following operations are involved:

. cubing and poaching for 1 • order of 30 to a temperature close to 85 ° C, soft fat,. cubing of ham,

. mixture of AT500 jelly, with the aroma of ham in 1/3 of hot broth (that is to say 1/3 of the total volume of broth expected) at around 60 or 70 ° C,. cubing of pork liver.

The jelly known under the name AT500 is gelatin.

By cubage, it is necessary to understand a cutting in the shape of small cubes of edge of dimension lower than about 5cm, for example from 2 to 3 cm.

The pretreatment step is followed by a step for preparing the dough 4, or mixed, comprising a chopping if necessary of the food products and a mixture with the foaming and stabilizing agents dissolved and / or mixed with a hot liquid.

In the example of the ham mousse, the following operations are thus carried out:

. mincing poached fats with 1/3 hot broth (60 to 70 ° C) mixed with foaming agents (caseinate 16, egg white, powder and whey isolate) for 2 minutes, at high speed (3000 rpm [rotation per minute ]) in a so-called "cutter" chopping apparatus, for example a cutter manufactured by the company MANURHIN of the CSV 603 type; . mixing and mincing of meats (liver + ham) with the mixture of AT500 jelly and ham flavor prepared in the previous step, and the different seasonings scheduled, for example for 3 minutes at high speed (knife speed of the cutter 3000 rpm).

Adding stabilizers (maltodextrins, Carrageenans) and the rest of the broth (1/3) and mixing again for about 3 minutes, at high speed. You can also add port and carmine at this point.

The ham paste obtained being very foaming, it is necessary to provide for filling the bowl of the cutter accordingly, for example only 40% of the nominal volume. The temperature of the dough at the outlet of the pretreatment step is, for example, of the order of 30 ° to 60 ° C, and advantageously 40 ° C. It is fed continuously (connection 5), with the dough prepared in 4, a first scraped surface exchanger; the dough is then stirred in the exchanger (step 6) for a first determined time, at a first temperature. Still in the example illustrating the invention, the first temperature will be, for example, of the order of 70 ° C., the stirring being carried out at a rotational speed of between 200 and 1100 rpm, for example 500 rpm, for a duration average of about 1 to 3 minutes, for example 2 minutes.

Then fed continuously (connection 7) with the dough, a second scraped surface exchanger in which said dough is stirred (step 8) for a second determined time, at a second temperature. In the example, the second temperature will for example be 125 ° C., the dough being brewed at a speed of between 200 and 1100 rpm, for example 1100 rpm, also for the order of 1 to 3 minutes, advantageously 2 minutes. Simultaneously with the heat treatment for sterilization and cooking of the dough in 6 and 8, an inert gas is continuously injected (step 9) into the dough upstream and / or downstream of the first and / or the second exchanger with a determined flow rate.

In the example, the flow rate of inert gas which is for example nitrogen, is a constant flow rate of the order of 2 1 / min per 100 kg of dough. However, this flow rate can, for example, go up to 10 1 / min per 100 kg of dough in other applications.

Finally, a third scraped surface heat exchanger is continuously fed (connection 10) with the dough, where the dough is stirred (step 11) for a determined third time, cooling the dough to a third temperature.

Still in the particular case of the ham mousse of the example, the third temperature will for example be of the order of 15 to 30 ° C., the brewing speed being between 200 and 1100 rpm, and of the order of 500 rpm in the example more particularly described, and the average duration of treatment, (third time determined) being of the order of 2 to 4 min, for example 3 min.

At the end of step 11, a sterile expanded food preparation is obtained.

This preparation is sent (step 12) in an aseptic medium, immediately after cooling, to a packaging unit, so as to avoid any contamination.

We will now describe the conditioning phase 2 of the food preparation, without it being necessary, this time, to illustrate more precisely by the example on the ham mousse, the steps of the process.

The packaging is for example carried out in plastic containers, for example in styrene, polypropylene, polyethylene, or also in aluminum, or any other suitable material making an oxygen tight barrier. First of all, the packaging unit is supplied with feed (step 13), for example with a rate of 150 containers per minute, of course depending on other parameters of use and in particular the flow of sterile expanded preparation at condition.

The containers are sterilized at 14, dried at 15, filled at 16 with the sterile expanded preparation, automatically and sequentially, at a rate depending on the flow rate of said expanded preparation conveyed at 12. The connection between phase 1 and phase 2 is made for example via piping supplying a rupture buffer tank between the continuous flow upstream of phase 1 and the discontinuous flow downstream of phase 2, discontinuity due to the filling of the containers, for example by series, each being filled with a determined volumetric dose. Once a series of containers have been filled, the lids are put on (step 17) by injecting an inert gas between the upper surface of the preparation present in the containers and the underside - lids, then the lids are sealed (step 18), the containers are marked (step 19), if necessary, and the containers are stored (step 20), without obligation to refrigerate them since the expanded preparation is sterile.

In Figure 2, there is shown in more detail, the main steps of the embodiment of the conditioning process (phase 2) more particularly described here.

This process, known in the context of more conventional packaging, had never, however, been used to package sterile expanded foams.

Each container 21 is sprayed internally with a jet 22 of hydrogen peroxide H ₂ 0 ₂ for sterilization (step 14). The container is then dried with hot air 23 (step 15) then filled with food preparation 24 (step 16).

The cover 25, supplied in the form of a ribbon, is sterilized by passing through a bath 26 of hydrogen peroxide, dried by a curtain of hot air 27, and spread over the upper part 28 of the container 21, one or two millimeters away from the top of the container.

An inert gas, for example nitrogen, is injected at 29 between the upper part 28 and the lower face 30 of the cover, so as to constitute an insulating layer 31. The lid is then sealed (step 18), in this case by heat-sealing, by a device 32 known in itself, applying pressure 33 to the periphery 34 of the container via the lid which it welds simultaneously.

A portion 35 of sterile, expanded, conditioned preparation is thus obtained, which can be stored for a long time at room temperature. FIG. 3 is an operating diagram of a device 40 for manufacturing a sterile expanded preparation, according to the embodiment of the invention more particularly described here.

The device comprises a hopper 41 for feeding the dough previously prepared in steps 3 and 4.

The dough is sucked by the pump 42 which supplies pressure, for example at 5 bars, and continuously at a determined flow rate, for example 150 kg / h, a first vertical exchanger 43, with a scraped surface, in the lower part 44 of said exchanger .

The dough is brewed and heated to a temperature between of about 40 ° C and about 80 ° C, for a period of a few minutes and d _e i'échangeur spring 43 in the upper part 45 of said exchanger supplying a second vertical exchanger 46 with a scraped surface at the bottom 47 of said exchanger, via a pipe 48. The dough is again brewed and heated in the exchanger 46, at a temperature this time between about 100 "C and about 130 ° C for a second determined time of duration corresponding to the first. spring in the upper part 49 of the exchanger and feeds via a second pipe 50, a third vertical exchanger 51 with a scraped surface, this time provided with means 52 for cooling the dough to a temperature below about 40 ° C. The cooling means are regulated in a manner known per se by being, for example, subject to the outlet temperature of the dough, obtained by means of a thermometer 53.

The pipes 48 and 50 are, in particular and for example, arranged to create pressure drops in the device and thus obtain a speed of the paste in said device corresponding to the durations of heat treatment sought and necessary, on the one hand to the destruction adapted bacterial and, on the other hand to obtain a cooked taste for food preparation. There are also other means for adjusting the speed of the dough, in particular and for example using a booster pump 42, at variable speed.

The food preparation obtained in the upper part 54 of the ^heat exchanger 51 feeds, via the piping 55, the packaging unit.

The device comprises means 56 for heating the exchangers 43 and 46, comprising for example a central 57 for supplying steam at 150 ° C. which supplies the exchangers with steam, at the bottom, via the supply network 58, the cooled steam being evacuated in the upper part of the exchangers by the pipes 59.

Remote-controlled valves 60, slaved to temperature measurements 61 (thermostats), arranged for example downstream of each of the two exchangers, allow to regulate the average temperature of the dough in the exchangers, in a manner known per se.

The device also comprises means 62 ⁵ for injecting a neutral gas (nitrogen for example) into the pulp, for example at the level of the pulp supply, in the lower part of each exchanger via remote-controlled regulating valves 63, and comprising an apparatus 64 for supplying nitrogen. The injection is carried out for example ⁰ perpendicular to the flow of dough, using a catheter with an internal diameter of 2 mm, a sintered injector, or a brine needle, at a flow rate of a few liters minutes, for example 2 1 / min.

Finally, each exchanger is provided with a rotary motor ⁵ 65 actuating rotating scraper blades.

The device 40 includes means 66 for controlling and adjusting the various operating members of the method comprising a 67 ° programmable automaton.

The control links 68 for this automaton are shown in phantom in FIG. 3.

Input-output connections also exist between this controller and the conditioning unit, this ⁵ which allows a smooth operation of the entire device more particularly described herein.

Finally, the device comprises means of routing (not shown) to the packaging unit 69, the sterile expanded preparation obtained at 55.

These means comprise for example a recovery pump (not shown) in series on the pipe 55. The constituent elements of the conditioning unit are, moreover, known per se and easily reproducible from the description of the process above .

The packaging unit can for example be constituted by an apparatus of the English Society METALBOX ENGINEERING, implementing a process of the type described with reference to FIG. 2, under the catalog reference Freshfill ^R ML4.

Finally, there is shown in Figure 4, an example of exchanger 70 with vertical scraped surface usable in the invention.

This type of exchanger is, for example, manufactured by the French company DUPRAT.

It comprises a body 71 elongated around an axis 72, provided with an axial cylindrical internal enclosure 73, comprising an inlet 74, at the bottom 75 of the exchanger, for the dough 76, and an outlet 77 at the top 78 .

The exchanger comprises an axial cylindrical rotor 79 disposed in the enclosure 73, actuated in rotation by a motor 80 and provided with blades 81 for mixing the paste injected into the enclosure.

The external cylindrical wall 82 of the enclosure is, moreover, a heat exchange wall with a heat transfer fluid 83 which circulates in an external casing 84 of the exchanger.

The operation of the device according to the invention will now be described, with reference, by way of example, to the manufacture and packaging of the sterile expanded ham foam already considered more particularly above.

Reference will be made in particular to FIG. 1. In order to be able to provide heat treatment and suitable packaging, it is necessary, before any use, to carry out a cleaning / disinfection operation of the entire device used.

By way of nonlimiting example, the following operations will be carried out in particular, for cleaning the device for manufacturing the sterile expanded food preparation and the means of transfer to the packaging unit: - washing with soda for 30 minutes at co-current at a rate of 120 l / h of flow.

- rinsing for 10 minutes with water, for example of the order of 200 l / h.

- treatment with hydrochloric acid for 30 min co-current, of the order of 120 1 hour.

- rinsing for 10 min with water at 200 l / h.

- steam treatment (for example of the order of 0.1 bar of pressure) against the current for 30 minutes and,

- rinse with co-current nitrogen for 30 minutes.

After this treatment, it will of course be necessary to no longer allow air or contamination to penetrate into the system, constituted by the manufacturing device proper and the supply means of the packaging unit.

The outlet of the sterile expanded food preparation at the container feed is also carefully decontaminated.

After preparation of the dough as indicated above, the hopper 41 is fed continuously or by "batch" (see FIG. 3).

The booster pump 42 then pushes the dough for example at a flow rate of 150 l / h into the first exchanger 43 with a scraped surface where it is heated to a temperature of the order of 70 ° via the steam circuit 58 during an average treatment time of 2 min with a knife rotation speed of the order of 500 revolutions / minute in the context, for example, of the use of a scraped surface exchanger with an internal dead volume of 5, 21.

The dough comes out at a temperature for example of the order of 65 ° C at the level of the piping 48 (internal volume for example: 2.61), which it traverses for an average duration of the order of 1 minute before penetrate from below into the exchanger 46 with a scraped surface, identical to the exchanger 43. This heats the dough at a temperature of the order of 125 "C while stirring it at a speed of the order of 1100 rpm and for an average treatment time of 2 minutes.

The dough then leaves the exchanger 46 from above and travels through the piping 50 (internal volume, for example 4 1), for a period of the order of 1 minute 30 seconds before reaching the third exchanger 51.

The temperatures of the exchangers 43 and 46 are regulated, as we have seen, via the supply of steam to their double jacket by the network 58.

Regulation takes place at the piping level through thermostats adjusted according to the temperatures sought in the exchangers.

The dough then enters the scraped surface cooling exchanger 51 itself supplied with cold water by the circuit and the exchanger 52.

The dough is treated in this exchanger 51 for an average duration of 3 min at a temperature of the order of 20 ° C, the dough being stirred with a speed of rotation of 500 rpm.

This third exchanger has an internal dead volume of 7.81 and an exchange surface equal to around 1.5 times the exchange surface of the exchangers

43 and 46.

Generally, in the embodiment of the invention more particularly described here, the first exchanger (E ^ will have an internal or substantially identical volume of vm ³ , the second exchanger

(E ₂ ), an identical internal volume of vM ³ , the third exchanger (E ₃ ), an internal volume of 1.5 x vm ³ , the connections between exchangers having for volume: connection E- _J -E ₂ : from 0 , 1 to 1 vm ³ , for example 0.5 xm3 and connection E ₂ -E ₃ : from 0.1 to 1 vm ³ , or for example 0.75 vm ³ .

The dough leaves the exchanger 51 at a temperature of the order of 20 ° C, regulated via a thermostat 53 and the corresponding regulation valve and is evacuated by the evacuation pipe 55, towards the conditioning unit 69. The sterile food preparation is taken up continuously by means of a pump (not shown) which feeds a tank under atmosphere sterile. The tank feeds, in a metered manner via, for example, five small feed metering pumps, the containers previously sterilized and presented automatically under the metering pumps. The containers are for example with a capacity of 50 cm3.

They are then heat sealed and removed on a conveyor belt in a manner known per se.

As goes without saying and as it follows from the above, the invention is in no way limited to the embodiment more particularly described here. On the contrary, it encompasses all the variants thereof and in particular those where the exchangers are not arranged vertically but horizontally, or even those where the sterilization of the containers is carried out in a different manner from that which has been more particularly described above. Other food preparations can be obtained. We can for example prepare fish moss by replacing the carmine with papirka (0.3%) or carrot moss containing: 30% pre-cooked carrots (25% vian), 10% fat instead of 15% , 0.2% of a flavor type 76974 GIVAUDAN (natural carrot extract), 0.3% paprika.

Claims

1. Method for manufacturing a sterile expanded preparation based on at least one food product, characterized in that from a dough prepared by mixing the food product, previously chopped if necessary, with a base teeming with at least one foaming surfactant and at least one texture stabilizing agent, a thermal treatment of bacterial destruction and cooking of the dough is carried out comprising a step (8) of stirring in a heat exchanger (46) with a scraped surface of said dough by heating it to a temperature between about 100 ° C and about 130 ^β C for a determined time, by injecting a gas into said dough during said heat treatment, to obtain an expanded preparation sterile, then the preparation is cooled (11) to a temperature below about 40 ^β C, the agents being in proportions such that, taking into account the quantities of gas injected and d e paste used, the expanded preparation formed after cooling has a density relative to water of less than 1, preferably between 0.9 and 0.3, and in a particularly advantageous manner of less than 0.7, and conditioning (2) said preparation expanded after cooling in containers (21) previously sterilized (14), which are then hermetically sealed and sterile (17, 18), so that portions (35) of sterile blended sterilized preparation, long storage at room temperature.

2. Manufacturing method according to claim 1, characterized in that the heat treatment of bacterial destruction and cooking comprises a first step (6) where stir the dough fed continuously in a first exchanger (43) with a scraped surface, by heating said dough to a temperature between about 50 ^β C and about 80 ^β C, for a first determined time , and a second step (8) in which said dough fed continuously from the first exchanger, in a second exchanger (46) with a scraped surface, by heating the dough to said temperature between 100 "C and 130 ° C , during a second determined time, the cooling (11) being carried out in a third exchanger with a scraped surface, fed continuously from the second exchanger (51), where the dough is stirred for a third determined time.

3. Manufacturing method according to any one of the preceding claims, characterized in that said determined times are between about 1 min and about 5 min. 4. Process for the continuous production of a plentiful preparation based on at least one food product, in which (3,

4) a paste by mixing the food product, previously chopped if necessary, with an abundant base comprising at least one foaming surfactant and at least one texture stabilizing agent chosen in particular from the gums, ) continuously with said dough a first scraped surface heat exchanger (43), where said dough is stirred (6) for a first determined time by heating the dough to a first temperature, then (7) is continuously fed with the dough thus obtained a second heat exchanger (46) with a scraped surface, in which said dough thus obtained is stirred (8) for a second time determined by heating the dough to a second temperature, an inert gas is injected (9) continuously into the paste simultaneously with its supply, upstream and / or downstream of the first and / or the second exchanger, with a flow rate determined as a function of the feed flow rate of said paste, then feeds (10) continuously with the dough a third scraped surface heat exchanger (51), where said dough is stirred (11) for a determined third time by cooling the dough to a third temperature, said method being characterized in that the agents are in proportions such that, taking into account the quantities of gas injected and of paste used, the expanded preparation formed after cooling has a density relative to water of less than 1, preferably between 0.9 and 0 , 3, and in a particularly advantageous manner less than 0.7, in that the first temperature is between about 50 "C and about 80 ^β C, the second temperature is between ord re 100 ° C and about 130 "C, and the third temperature is between about 10 ° C and about 40 ° C, said times determined, average brewing time , being between about lmn and about 5 min, so that a sterile expanded preparation is obtained from said paste, and in that one conveys (12) in an aseptic medium said expanded preparation sterile, immediately after cooling, to a conditioning unit located near said third exchanger, the preparation is conditioned (16, 17, 18), by feeding (13, 14, 15) automatically in aseptic medium with said preparation, containers previously sterilized, then hermetically sealed and sterile, so that there are thus obtained portions (35) of sterile blended sterile preparation, which can be stored for a long time at room temperature.

5. A method of manufacturing an expanded preparation based on at least one food product according to any one of the preceding claims, characterized in that the food product is meaty.

6. Method according to any one of the preceding claims, characterized in that the second temperature is greater than 120 ° C, and advantageously equal to around 125 "C.

7. Method according to any one of the preceding claims, characterized in that the abundant base comprises several foaming surfactants chosen from sodium caseinate, egg white, whey isolate, soy isolate , the pea isolate, the skimmed milk powder, the powdered pig blood plasma, preferably so that the quantity of pure protein provided is less than 10%, and advantageously equal to ^" of the order 6% by total weight of the preparation.

8. Method according to any one of the preceding claims, characterized in that the abundant base comprises several texture stabilizing agents chosen from gums such as xanthan, guar, carrageenans, these stabilizing agents being in a proportion of approximately 0.1 to 1%, and advantageously 0.5% by total weight of the preparation.

9. Method according to any one of the preceding claims, characterized in that the abundant base comprises: between 0.5 and 2% by weight, preferably between 1 and 1.5% of sodium caseinate, between 0.5 and 2% by weight, preferably between 1 and 1.5% powdered egg white, between 2 and 6% by weight, preferably between 4 and 5% of ^"whey isolate between 1 and 3% by weight, preferably 2% maltodextrins. between 0.2 and 1% by weight, preferably 0.5% of carrageenans.

10. A method of manufacturing a sterile ham mousse according to claim 9.

11. A method of manufacturing a profusion preparation according to any one of the preceding claims, characterized in that incorporates into the dough comprising the product, previously chopped if necessary, whole pieces of said product, before treatment thermal.

12. Device for the continuous production of a floured food preparation from a dough prepared by mixing at least one food product, previously chopped if necessary, with a flouring base comprising at least one foaming surfactant and at least one texture stabilizing agent, the device comprising: - means (41, 42) for continuously supplying pressure and at a determined rate, with said paste, to a first surface heat exchanger (43) scraped, two exchangers with scraped surface for heat treatment and cooking of the dough, namely said first exchanger (43), and a second exchanger (46), - a third exchanger (51) for cooling the dough, and - means (62) for injecting a gas into the dough with a flow rate determined as a function of the feed rate of said dough, characterized in that the device comprises: means (56) for heating the dough in the first exchanger, to a temperature between about 40 ° C and about 80 ° C, in the second exchanger, to a temperature between l '' order of 100 ° C and of the order of 130 ^e C, means (52) for cooling the dough in the third exchanger, to a temperature below about 40 ° C, so that obtains a sterile expanded preparation from said paste, suitable for being packaged, and in that it comprises - means for conveying, in an aseptic medium, said sterile expanded preparation, immediately after cooling, to a packaging unit (69) located near said third exchanger, and said packaging unit (69) comprising means for automatically feeding aseptic medium with said preparation, containers (21) previously sterilized and means for sealing automatically, her metric and sterile of said containers, so that thus obtained portions of sterile expanded preparation conditioned, in said sealed containers, long storage at room temperature.

13. Application of the device according to claim 12, in the manufacture of sterile expanded preparation based on meat products.

14. Device according to any one of claims 12 and 13, characterized in that the respective heat exchange surfaces of the exchangers are:

- first exchanger (43): a x m2

- second exchanger (46): ax m2 - third exchanger (51): 1.5 xax m2 a being a determined variable surface.

15. Device according to any one of claims 12, 13 and 14, characterized in that it further comprises a fourth heat exchanger with scraped surface.

16. Abundant food preparation based on meat, fish, dairy product, fruit, vegetable, chocolate or a mixture of these products, characterized in that it is sterile and in that it contains a abundant base comprising: a) one or more foaming surfactants, resistant to a temperature above 100 ° C., preferably around 120 "C chosen in particular from proteins, b) one or more texture stabilizing agents chosen in particular from the gums, the agents a) and b) being in proportions such that the food preparation formed at a density less than 1, preferably between 0.9 and 0.3 and in a particularly advantageous manner, less than 0.7.

17. Abundant food preparation based on meat, fish, dairy product, fruit, vegetable, chocolate as obtained by, - mixing one or more of these products with an abundant base comprising: a) a or several foaming surfactants, resistant to a temperature above 100 ° C, preferably around 120 ° C chosen in particular from proteins, b) one or more texture stabilizing agents chosen in particular from gums, agents a) and b) being in proportions such that the food preparation formed at a density less than 1, preferably between 0.9 and 0.3 and so particularly advantageous, less than

0.7 sterilization by heating at a temperature between about 100 "C and about 130 ° C for a time greater than about 1 min.

18. Expanded food preparation according to any one of claims 16 and 17, characterized in that the expanded base is based on meat or fish.

19. Food preparation expanded according to any one of claims 16 to 18, characterized in that it comprises a proportion of at least one of these products in the form of pieces.

20. Expanded food preparation according to any one of claims 16 to 19, characterized in that its lipid content is less than 20% optionally around 0 and preferably located around 10% by total weight.

21. Expanded food preparation according to any one of claims 16 to 20, characterized on the one hand in that the foaming surfactants are chosen from sodium caseinate, egg white, whey isolate, soy isolate, pea isolate, skimmed milk powder, pork blood plasma powder, preferably so that the amount of pure protein provided is less than 10%, particularly advantageously of the order of 6% by total weight, and on the other hand in that the texture stabilizing agents are gums such as xanthan, guar, carrageenans, these stabilizing agents being present in a proportion of approximately 0 , 1 to 1% in a particularly advantageous manner approximately 0.5% by total weight.

22. Food preparation according to any one of claims 16 to 21, characterized in that it comprises: - between 0.5 and 2% by weight, preferably between 1 and

1.5% sodium caseinate, between 0.5 and 2% by weight, preferably between 1 and

1.5% of powdered egg white, between 2 and 6% by weight, preferably between 4 and 5% of whey isolate, between 1 and 4% by weight, preferably 2 to 3% of maltodextrins, - between 0.2 and 1% by weight, preferably 0.5% of

Carrageenans.

23. Food preparation according to any one of claims 16 to 21, characterized in that it also comprises gelling agents chosen in particular from alginates, agar, carob flour, guar flour, gum tragacanth, gum arabic, pectins, karaya, damar, acacia, gelatin.

24. Food preparation according to any one of claims 16 to 23, characterized in that it is a sterile meat-based foam comprising pieces, preferably in an amount less than 25% by total weight.

25. Food preparation according to any one of claims 16 to 24, characterized in that it comprises additional products such as flavors, flavor enhancers has _es and food additives.

26. Food preparation according to any one of claims 16 to 25, characterized in that it has the following composition:

White ham 25% by weight Pre-cooked soft fat 15

Hot broth 41,738

Caseinate 116 1.23

White egg powder 1,285 Whey isolate 4,667

Passeli SA2 (maltodextrins) 2

Carrageenans (thickener, 0.5 gelling agent)

Jelly AT 500 (gelatin) 1.5

Ham flavor 1

Fine salt 0.6

Dextrose or glucose 0.5 Pluralin 20 (glucose syrup DE20) 0.5

Tari K7 (cooking) polyphosphate 0.3 Sodium ascorbate 0.03

Glutamate (flavor enhancer) 0.15

Pepper 0, 10

Onion powder 0.10

Pork liver 2

Red port 1.5

Carmine 0.3